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S hielded Metal Arc Welding Principles Chapter 11
Objectives   ,[object Object],[object Object],[object Object],[object Object]
Objectives ,[object Object],[object Object],[object Object],[object Object],[object Object]
Shielded Metal Arc Welding (SMAW) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
SMAW American Welding Society Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Process Capability ,[object Object]
SMAW Advantages ,[object Object],[object Object],[object Object],[object Object],[object Object]
SMAW Operating Principles ,[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Welding Process ,[object Object],[object Object],[object Object],[object Object]
SMAW Operating Principle American Welding Society Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Welding Power Sources ,[object Object],[object Object],[object Object],[object Object],[object Object]
Welding Power Sources ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Type of Output Slope ,[object Object],[object Object],[object Object],[object Object],[object Object]
Output Slope ,[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Output Slope ,[object Object],[object Object],[object Object],[object Object],[object Object]
Typical Output Slopes Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Four Types of Power Source ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Four Types of Power Source ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Power Sources ,[object Object],[object Object],[object Object],[object Object],[object Object]
Constant Current  Welding Machines ,[object Object],[object Object],[object Object],[object Object]
Constant Current Output Slope ,[object Object],[object Object],[object Object],[object Object],[object Object]
Constant Current  Output Slope Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Some jobs require steep volt-ampere curve Other jobs use less steep    volt-ampere curve
Open Circuit Voltage ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Open Circuit and Arc Voltage ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Open Circuit and Arc Voltage ,[object Object],[object Object],[object Object],[object Object],[object Object]
Motor Generator Welding Machines   ,[object Object],[object Object],[object Object],[object Object]
Motor-Generator  Welding Machine Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Hobart Brothers Co. Sturdy steel lifting eye  Large voltmeter  Calibrated dial for easy, fine adjustment of heat and relation between voltage and current Outer wheel and dial for selecting desired welding range Stop button
Motor-Generator  Welding Machine Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Hobart Brothers Co. Ground cable    connector  Optional steel guard Heavy-duty ball    bearings Pressed steel bearing cap Arc welded copper  squirrel cage rotor Motor stator  Heavy steel fan
Motor-Generator  Welding Machine Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Hobart Brothers Co. Steel frame  Fourpole "Multi-Range"   generator  Large commutator  Heavy-duty metallic   graphite brushes Heavy-duty ball   bearings Pressed steel bearing cap Arc welded steel frame
Motor-Generator  Welding Machine Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Hobart Brothers Co. Removable steel covers  Heavy-duty single unit    steel shaft Polarity switch  Welding cable connector  Large ammeter Steel turret top with    removable cover
Motor Generator Welding Machine for SMAW Variable voltage control Instruction on the    Name-plate Polarity switch Current control Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Toggle switch Constant voltage The Lincoln Co.
External Construction of d.c. Motor Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. The Lincoln Electric Co.
Internal Construction of a D.C. Motor Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. The Lincoln Electric Co.
Motor Generator Desirable Characteristics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Generators ,[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Generators used  in the field Miller Electric Mfg. Co. The Lincoln Electric Co.
Sizes ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Maintenance ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Start and Stop Buttons ,[object Object],[object Object],[object Object],[object Object]
Polarity Switch ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Volt-Ampere Meters ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Current Controls ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Dual Tapped-Current Control ,[object Object],[object Object],[object Object],[object Object],[object Object]
Dual Continuous Control ,[object Object],[object Object],[object Object],[object Object]
Engine Driven Generator Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Capable of SMAW, GTAW, SMAW, FCAW and PAC. Miller Electric Mfg. Co. Miller Electric Mfg. Co.
Remote Control ,[object Object],[object Object],[object Object],[object Object]
Air Filters ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
D.C. Transformer-Rectifier Welding Machines ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. The Lincoln Electric Co. Miller Electric Mfg. Co.
Transformer-Rectifier Machines ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
A.C.-D.C. Transformer-Rectifier Welding Machines ,[object Object],[object Object],[object Object],[object Object],[object Object]
A.C.-D.C. Transformer-Rectifier Welding Machines Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. A 300 amp a.c.-d.c. GTAW/SMAW machine. Portable SMAW/GTAW welding machine A 300 amp model shown in use The Lincoln Electric Co. The Lincoln Electric Co. Miller Electric Mfg. Co.
A.C. Transformer Welding Machines ,[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. The Lincoln Electric Co. Miller Electric Mfg. Co
Advantages of a.c. Power Sources ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
D.C. and A.C.-D.C. Inverter Welding Machines ,[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Miller electric Mfg. Co. The Lincoln Electric Co.
Cost Comparisons:  Arc Power Sources ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],See Table 11-2 for more comparisons
Multiple-Operator Systems ,[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. ,[object Object],[object Object],[object Object],Miller Electric Mfg. Co.
Power Supply Ratings ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Current Output ,[object Object],[object Object],[object Object],[object Object]
Open Circuit Voltage ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Duty Cycle ,[object Object],[object Object],[object Object],[object Object],[object Object]
Efficiency ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Power Factor ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Power Cable ,[object Object],[object Object],[object Object],[object Object],[object Object]
Electrode and Work Cable ,[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. The Lincoln Electric Co.
Cable Core Construction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Work Cable ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],See Table 11-3 to help choose the right size of welding cable
Cable Lugs ,[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Work Clamps ,[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Spring loaded C-clamp  Lenco dba NLC. Inc. Lenco dba NLC. Inc. Rotary type Lenco dba NLC. Inc. This clamp stops twisting and turning of  welding cable  where work rotates.  Clamp  welded to part, thus permits work clamp to be  attached in seconds.  It is generally used in fabricating  tanks, pressure vessels, and on weld positioners.
Quick Connector ,[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. This connector has cam-type action that ensures positive stop  and lock and cannot come loose or accidentally fall apart. Lenco dba NLC. Inc.
Metal Electrode Holders ,[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Lenco dba NLC. Inc.
Metal Electrode Holders ,[object Object],[object Object],[object Object],[object Object]
Spring Type Electrode Holder Lenco dba NLC. Inc. Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Short-stub Electrode Holder Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Cable connections Special extruded copper-alloy body High welding current conductance One-ton pressure  contact Lifeguard insulation  Entirely insulated Bernard Welding Equipment Co. Holds electrodes burned to very short stub. Twist-type locking device permits electrode- gripping power in excess of 2,000 pounds.
Angle-head Electrode Holder Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Jackson Products Co. Available in sizes of 400 and 600 amperes  and takes electrodes from 1/16 through  5/16 inch in diameter. Shorter and lighter  than other holders of comparable capacity.
Other Electric Arc processes ,[object Object],[object Object],[object Object],[object Object]
Carbon Arc Welding ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Twin Carbon Electrode Holder Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. The Lincoln Electric Co. Two leads are required because the arc is created between the two electrodes. Metal shield to protect welder's hand from intense heat. Larger than the  metal electrode  holder Holder is water cooled
Atomic-Hydrogen Arc Welding ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Atomic-Hydrogen Electrode Holder Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. General Electric Co.
Atomic-Hydrogen Arc Welding ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Hand and Head Shields ,[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Fibre-Metal Products Co. Hand shield so person may hold shield in front of face
Hand and Head Shields ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Fibre-Metal Products Co. Fibre-Metal Products Co.
Hand and Head Shields ,[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Fibre-Metal Products Co. Wilson Products Flip-front welding helmet permits welder to  inspect and brush weld without lifting the hood. Chrome leather helmets ideal for  hard-to-get-into areas.
Head Shield Lens ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Auto-darkening Electronic Filter Helmet ,[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. . Jackson Products Co.
Safety Glasses ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. © RobCrandall/The Image Works
Protective Clothing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Department of Labor
Protective Clothing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display. Miller  Electric Mfg. Co.
Protective Clothing Copyright © The McGraw-Hill Companies, Inc.  Permission required for reproduction or display.
Further Protection ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Chapter11

  • 1. S hielded Metal Arc Welding Principles Chapter 11
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  • 5. SMAW American Welding Society Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
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  • 10. SMAW Operating Principle American Welding Society Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
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  • 16. Typical Output Slopes Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
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  • 22. Constant Current Output Slope Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Some jobs require steep volt-ampere curve Other jobs use less steep volt-ampere curve
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  • 27. Motor-Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Hobart Brothers Co. Sturdy steel lifting eye Large voltmeter Calibrated dial for easy, fine adjustment of heat and relation between voltage and current Outer wheel and dial for selecting desired welding range Stop button
  • 28. Motor-Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Hobart Brothers Co. Ground cable connector Optional steel guard Heavy-duty ball bearings Pressed steel bearing cap Arc welded copper squirrel cage rotor Motor stator Heavy steel fan
  • 29. Motor-Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Hobart Brothers Co. Steel frame Fourpole "Multi-Range" generator Large commutator Heavy-duty metallic graphite brushes Heavy-duty ball bearings Pressed steel bearing cap Arc welded steel frame
  • 30. Motor-Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Hobart Brothers Co. Removable steel covers Heavy-duty single unit steel shaft Polarity switch Welding cable connector Large ammeter Steel turret top with removable cover
  • 31. Motor Generator Welding Machine for SMAW Variable voltage control Instruction on the Name-plate Polarity switch Current control Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Toggle switch Constant voltage The Lincoln Co.
  • 32. External Construction of d.c. Motor Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. The Lincoln Electric Co.
  • 33. Internal Construction of a D.C. Motor Generator Welding Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. The Lincoln Electric Co.
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  • 44. Engine Driven Generator Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Capable of SMAW, GTAW, SMAW, FCAW and PAC. Miller Electric Mfg. Co. Miller Electric Mfg. Co.
  • 45.
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  • 50. A.C.-D.C. Transformer-Rectifier Welding Machines Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. A 300 amp a.c.-d.c. GTAW/SMAW machine. Portable SMAW/GTAW welding machine A 300 amp model shown in use The Lincoln Electric Co. The Lincoln Electric Co. Miller Electric Mfg. Co.
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  • 71. Spring Type Electrode Holder Lenco dba NLC. Inc. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
  • 72. Short-stub Electrode Holder Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Cable connections Special extruded copper-alloy body High welding current conductance One-ton pressure contact Lifeguard insulation Entirely insulated Bernard Welding Equipment Co. Holds electrodes burned to very short stub. Twist-type locking device permits electrode- gripping power in excess of 2,000 pounds.
  • 73. Angle-head Electrode Holder Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Jackson Products Co. Available in sizes of 400 and 600 amperes and takes electrodes from 1/16 through 5/16 inch in diameter. Shorter and lighter than other holders of comparable capacity.
  • 74.
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  • 76. Twin Carbon Electrode Holder Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. The Lincoln Electric Co. Two leads are required because the arc is created between the two electrodes. Metal shield to protect welder's hand from intense heat. Larger than the metal electrode holder Holder is water cooled
  • 77.
  • 78. Atomic-Hydrogen Electrode Holder Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. General Electric Co.
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  • 88. Protective Clothing Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
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